Reduced noise appliance

ABSTRACT

An appliance provides a platform having a platform bottom and a platform base which supports a main base. A motor is carried by the platform base and rotates a ventilation fan which has a plurality of radial vanes with a fan aperture centrally positioned therein, such that the ventilation fan draws air in through an intake port provided by the platform. A fan shroud encloses the ventilation fan and has a shroud opening. The fan shroud extends from the platform base toward the platform bottom, wherein the main base surrounds the motor. The main base has an outer housing with at least one housing port, wherein rotation of the ventilation fan draws air into the fan aperture from the intake port, through the shroud opening, and expels the air radially from the plurality of radial vanes so that the air flows through the motor and out the housing port.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Continuation application of Application Ser. No.15/166,742 filed May 27, 2016, which claims priority of U.S. ProvisionalApplication Ser. No. 62/167,961 filed May 29, 2015, both of which areincorporated herein by reference.

TECHNICAL FIELD

Generally, the present invention relates to a motor-operated appliancewhich includes a motor shaft with a coupling interface. Specifically,the present invention provides a motor-operated appliance which includesimproved air flow features to reduce noise at high rotational speeds ofthe motor.

BACKGROUND ART

Motors are commonly used with appliances and the like to rotate acomponent of the appliance at a high operational speed. Some applianceconfigurations require that a portion of the appliance be de-coupledfrom the motor/motor base to facilitate their use. Examples of suchappliances are consumer and industrial mixers, blenders and the like,wherein a container or bowl has a fixture that couples with a motorshaft.

Coupling a motor shaft to a receiving component is problematic in thatthe devices may be slightly misaligned due to poor tolerances. Pooralignment of the structure surrounding the shaft and receiving componentmay also contribute to misalignment.

Another problem with current appliances is that cooling air is firstdrawn in through and over the motor and then expelled by a fan.Conventional ventilating appliances are thermally managed by “pulling”air from a base section and exhausting that air through the appropriateport areas designed into the appliance base. This means that the noisespectrum generated at the ventilating fan exhaust perimeter isintroduced directly into exhaust air passages and is transferred out toambient. Moreover, such prior art configurations first transfer heatedair from the motor through the fan. It is known that directing heatedair through the fan reduces mass air flow, thus requiring more work bythe motor and more air flow is then required for cooling. Thisadditional work required by the motor in turn generates more noise fromthe fan. Prior art solutions to this problem include elaborate airpassage baffling and the addition of sound deadening material to achievea low system noise output, which adds complexity and cost to theconfiguration.

Misalignment of the motor shaft with the receiving component and poorheat management contribute to premature failure of the shaft and/or thereceiving component and prevents the appliance from obtaining higherrotational speeds. Therefore, there is a need in the art to improve theair management features and to accommodate or improve the misalignmentproblem.

SUMMARY OF THE INVENTION

In light of the foregoing, it is a first aspect of the present inventionto provide a reduced noise appliance.

It is another aspect of the present invention to provide an appliance,comprising a platform having a platform bottom and a platform base whichsupports a main base, the platform having at least one intake port, amotor carried by the platform base, the motor rotating a ventilation fanhaving a plurality of radial vanes with a fan aperture centrallypositioned therein, the ventilation fan drawing air in through the atleast one intake port, and a fan shroud enclosing the ventilation fanand having a shroud opening, wherein the fan shroud extends from theplatform base toward the platform bottom, the main base surrounding themotor, the main base having an outer housing with at least one housingport, wherein rotation of the ventilation fan draws air into the fanaperture from the at least one intake port, through the shroud opening,and expels the air radially from the plurality of radial vanes so thatthe air flows through the motor and out the at least one housing port.

Still another aspect of the present invention is to provide anappliance, comprising a main base, a platform having a platform bottomand a platform base which supports the main base, the platform having atleast one intake port, a motor carried by the platform base andextending into the main base, the motor rotating a ventilation fan thatdraws air in through the at least one intake port, and a fan shroudcarried by the platform base and enclosing the ventilation fan, the fanshroud having a centrally disposed shroud opening, wherein the fanshroud extends from the platform base toward the platform bottom,wherein the centrally disposed shroud opening faces the platform bottomand the main base surrounds the motor, the main base having an outerhousing with at least one housing port, wherein rotation of theventilation fan draws air from the at least one intake port, through thecentrally disposed shroud opening, and expels the air through the motor,into the main base and out the at least one housing port.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features and advantages of the present invention willbecome better understood with regard to the following description,appended claims, and accompanying drawings wherein:

FIG. 1 is a partial schematic drawing of an appliance according to theconcepts of the present invention;

FIG. 2 is a schematic drawing of a multi-sided ball receivable in apocket of a rotatable component according to the concepts of the presentinvention;

FIG. 3 is an end view taken along lines 3-3 of FIG. 2 of the multi-sidedball according to the concepts of the present invention;

FIG. 4 is an end view taken along lines 4-4 of FIG. 2 of the pocketaccording to the concepts of the present invention; and

FIG. 5 is schematic diagram of a reverse air flow motor housingaccording to the concepts of the present invention.

BEST MODE FOR CARRYING OUT THE INVENTION

Referring now to the drawings, and in particular to FIGS. 1-2, it can beseen that an appliance, which provides reduced-noise features, isdesignated generally by the numeral 10. The appliance includes a mainbase 12 which carries a motor 14. The motor 14 may be powered by mainspower through an electrical cord 16 which supplies electricity to themotor, or the motor may be powered by a separate power supply or anumber of batteries (not shown). Extending from the motor 14 is a shaft20 which may be rotated in either direction.

A multi-sided ball 22 is secured to the end of the shaft 20 and isreceived by an attachment 26. As used herein, the term ball refers to agenerally rounded shape which has one side truncated and secured to theshaft and an opposite side which may or may not be truncated. In someembodiments the attachment 26 may be a container such as a mixing bowlor pitcher as is used in a blender, wherein the attachment 26 includes arotatable component 28. The rotatable component 28 is configured toreceive the multi-sided ball 22.

As best seen in FIGS. 2-4, the multi-sided ball 22 includes a body 34which provides a trailing end that is secured to the shaft 20 and whichis opposite a leading end 38 which is received in the rotatablecomponent 28. The body 34 includes at least two rounded sides 40 whichextend from the trailing end 36 to the leading end 38. Any number ofsides may be employed. In the embodiment shown, the ball 22 provides forsix rounded sides in a quasi-hexagon configuration. Each rounded side 40provides an apex 42 at about a midpoint of the ball between the trailingend 36 and leading end 38. Each rounded side intersects with an adjacentrounded side at an edge 39. The ball 22, and in particular the roundedside 40 provides a rounded curvature with a radius appropriate for thesize of the receiving pocket.

The rotatable component 28 includes a paddle or blade used by theappliance 10 to perform its desired function. The rotatable component 28provides a pocket 50 for receiving the multi-sided ball 22. The pocket50 includes a bottom surface 52 and a multi-sided wall 54 wherein thenumber of sides of the multi-sided wall 54 match the number of roundedsides provided by the ball 22. In the present embodiment, each wall 54may be provided at about a right angle with respect to the bottom 52.The angular configuration of the multi-sided walls 54 is similar tothose provided by the sides 40 of the ball 22. The ball 22 isdimensionally sized so as to be receivable within the pocket 50. Theapex 42 of each side 40 is sized so as to be in close proximity to thewall 54 when the ball is received in the pocket. In some embodiments theapex 42 may be frictionally fit with the corresponding wall 54.

In some embodiments, the position of the ball 22 and the pocket 50 maybe switched. In other words, the pocket 50 may be integral with themotor shaft 20 and the multi-sided ball 22 may be integral with therotatable component 28. Such a configuration provides the sameadvantages.

During operation of the appliance, it will be appreciated that as theshaft 20 turns, the rounded sides of the ball 22 engage the walls 54 ofthe pocket 50. The ability to slightly angularly insert the shaft andassociated ball 22 into the pocket 50 accommodates any misalignmenttherebetween while still providing the desired torsional forces from theshaft to the rotatable component 28. It has been found that such aconfiguration provides for the desired torsional properties while alsoreducing noise generated from shafts that do not provide for amulti-sided ball as shown and described.

Referring now to FIG. 5, it can be seen that a reverse air flow motorhousing is designated generally by the numeral 100. The motor housing100 includes the main base 12 which carries the motor 14 from whichextends the motor shaft 20. The shaft 20, in this embodiment, mayprovide for the multi-sided ball 22 or some other configurationreceivable in the attachment 26. It will be appreciated that theappliance 10 may not provide the ball 22 and only the featuresassociated with the housing 100.

The main base 12 includes a lower platform 102 which may include aplatform bottom 104 from which extends a platform sidewall 106.Supported by the platform sidewall 106 is a platform base 108 which maysupport and/or carry the motor 14. The platform sidewall 106 may provideat least one air intake port 110. Skilled artisans will also appreciatethat in some embodiments the air intake port 110 may be provided or mayextend through the platform bottom 104 wherein the platform bottom 104may be elevated by a plurality of feet 112 which are supported by anyavailable surface.

A ventilation fan 120, which may be considered as part of the motor 14,is attached to an end of the shaft 20 opposite the attachment end thatcarries the multi-sided ball 22 or other attachment feature. Theventilation fan 120 includes a fan aperture 122 at the approximatecenter thereof which may be aligned with the shaft 20. A plurality ofradial vanes 124 are provided by the fan wherein the aperture 122 ispositioned centrally within the radial vanes 124. A fan shroud 130partially encloses the fan 120 and is mounted to an underside of theplatform base 108. The fan shroud may also include a fan end plate 132which may be mounted to the platform base 108. The fan shroud 130 mayprovide for a centrally disposed shroud opening 134 which is alignedwith the fan aperture 122. In the present embodiment, at least one plateaperture 136 may extend through the fan end plate 132. Skilled artisanswill appreciate that although the fan end plate 132 may offer noisereduction advantages, other structural features within the housing 100also reduce noise generated by the ventilation fan 120. As shown, theshroud 130 extends into the lower platform 102 substantially its entirewidth. However, in some embodiments, it will be appreciated that theshroud may be positioned at any desired depth or may be flush with theplatform base 108. In other words, the shroud opening 134 may be in thesame plane as the platform base 108.

The motor 14 includes a pair of opposed carbon brushes 138 which arepositioned so as to contact a rotor 140 as is well known in the art. Therotor 140 is fixedly attached to the shaft 20 which extends through amotor core 142. A brush bracket 144 may be employed to hold the brushes138 in place. Motor windings 146 are spaced from and surround the coreas is also well known in the art. Bearings 148 are disposed around andnear each end of the shaft so as to rotatably support the shaft andallow for rotation thereof when electric power is applied to the brushes138. The brush bracket 144 may also hold the bearings 148 and may alsobe structurally supported by the fan end plate 132. In some embodiments,the brush bracket 144 may be supported or carried by the end plate 132,and in other embodiments the brush bracket 144 may be supported orcarried by the platform base 108. And in other embodiments, acombination of the end plate 132 and the base 108 may support or carrythe brush bracket 144 and as a result the other parts of the motor 14.

A casing 150 spaces and supports components of the motor 14 and mayextend from the brush bracket 144 and/or the fan end plate 132. Thecasing 150 carries at least one fastener 151 that may extendtherethrough. The casing 150 may be spaced apart from the motor core 142so as to form casing passages 152 therebetween. An end bracket 154 maybe secured around and mounted to the casing 150 at an end of the motoropposite the end plate 132. The bracket 154 also functions to hold thebearings 148 in an operative position with the shaft 20. The at leastone fastener 151 effectively secures the brush bracket 144, the casing150 and the end bracket 154 to one another. The end bracket 154 mayprovide at least one bracket opening 156 therethrough which may beradially oriented. In other words, the at least one bracket opening 156extends through the end bracket and is contiguous with the casingpassage 152. In the embodiment shown, the end bracket 154 may bemaintained within the motor housing 100.

Maintained within the motor housing 100 may be an inner support 160. Theinner support 160 may include a platform leg 162 which may be attachedto, otherwise supported by or maintained in close proximity to theplatform base 108 or other nearby structure. At an end opposite theplatform leg 162 is a casing leg 164 which may be attached to, otherwisesupported by or maintained in close proximity to the motor casing 150.As shown, a casing support 166 radially extends from the casing leg 164and effectively from the casing. A platform support 168 may extendsubstantially perpendicularly from the casing support 166 and isconnected to the platform leg 162. It will be appreciated that the innersupport 160 may provide structural support of the motor with respect tothe platform base 108. The support 160 may also provide a sound barrierto assist in muffling noises generated by operation of the motor 14and/or the ventilation fan 124. The inner support 160 substantiallysurrounds a lower half of the motor 14 while also providing structuralsupport which maintains an airflow in a generally axial directionthrough the casing and in an opposite generally axial direction betweenthe inner support and an outer housing 170 as will be described.

The motor housing 100 may include an outer housing 170 which may extendradially from the end bracket 154 and surrounds or substantiallyencloses the inner support 160 and is further supported by the platformbase 108. The outer housing 170 includes a housing sidewall 172 whichhas a housing end 174 with a shaft opening 176 therethrough. The housingend 174 may be adjacent to and/or in a contacting positionalrelationship with the appropriate facing surface of the end bracket 154.In any event, it will be appreciated that the shaft 20 extends throughthe shaft opening 176. The outer housing may be provided with at leastone housing port 178. In one embodiment, the housing sidewall 172 mayprovide the port 178. In the embodiment shown, the housing port 178,which may also be called a sidewall port, is juxtapositioned near theinner support 160. However, the sidewall ports 178 may be positionedanywhere along the housing sidewall 172 and about an outer periphery ofthe housing end 174 that is radially removed from the end bracket 154.

Together, the inner support 160 and the outer housing 170 provide apassageway for air exiting from the motor casing 150 to be directed toambient. In the embodiment shown, the outer housing together with theinner housing route air flow that passes from the bracket opening 156toward the ports 178. The casing support 166, the housing end 174, thecasing 150 and an upper portion of the sidewall 172 form a cavity 179which is contiguous with the end bracket aperture 156. Air that exitsfrom the bracket opening 156 and which carries the associated noisespectrum, deflects off of the various surfaces that form the cavity and,as a result, serves to reduce the noise. The platform support, theplatform leg, and/or the platform base, and a lower portion of thesidewall 172 form a chamber 180, which may be annular in shape. Thechamber 180 is contiguous with the cavity 179 and the sidewall ports178. After collecting in the cavity 179, the air flow from the fan 124is directed into the chamber and then out to ambient.

In operation, rotation of the shaft 20 operates the appliance aspreviously described. Simultaneously, rotation of the shaft results inrotation of the ventilation fan 120 which generates an airflowrepresented by the enlarged arrows in FIG. 5. Rotation of the fan 120results in air being drawn in through the air intake port or ports 110and through the shroud opening 134. Subsequently, the air travelsthrough the fan aperture 122 and is then expelled radially by the vanes124 into the fan shroud 130. The apertures 136 extend through the fanend plate 132 and allow for the ventilation air to then travel throughthe motor casing openings and/or passages 152 between the core and thecasing as shown in FIG. 5. Skilled artisans will appreciate thatrotation of the shaft and electricity flowing through the electricalcomponents within the motor generate heat and the flowing ventilationair transfers the heat and expels it out through the bracket openings156. This air then travels within the cavity 179 and the chamber 180between an inner surface of the outer housing 170 and an exteriorsurface of the inner support 160 until such time that it passes throughthe side wall ports 178.

The present reverse air flow motor housing 100 ventilates air flow andthe associated noise spectrum in a direction that is reverse, leading tothe benefit of reduced noise. In contrast to the prior artconfigurations, air is “pushed” into a motor housing by the ventilatingfan. The system ventilation or cooling air and noise spectrum aredirected into the housing interior and cooling air thermally manages thehousing interior components and is subsequently exhausted to ambientthrough housing section port areas. The appliance housing and relatedstructure also acts as a muffler, reducing the noise amount introducedinto ambient. Noise reduction may be accomplished without the additionof a noise abatement material or additional air passage baffling. Assuch, the present platform and housing configuration serves dualpurposes in that it houses the components and also muffles fan noise.Skilled artisans will appreciate that if desired further abatementstrategies, such as the use of sound dampening material, may furtherreduce noise. The disclosed configuration allows noise abatement withoutthe need to increase the size of the housing in view of the housing'sdual role of housing components and abating noise. Cooling fan noisegenerated by the fan air intake feature is substantially less than theexhaust perimeter noise. This fact gives the reverse air flowconfiguration a noise platform lower than conventional ventilatedappliance systems where exhaust noise is directly exposed to ambientair.

Thus, it can be seen that the objects of the invention have beensatisfied by the structure and its method for use presented above. Whilein accordance with the Patent Statutes, only the best mode and preferredembodiment has been presented and described in detail, it is to beunderstood that the invention is not limited thereto or thereby.Accordingly, for an appreciation of the true scope and breadth of theinvention, reference should be made to the following claims.

What is claimed is:
 1. An appliance, comprising: a platform having aplatform bottom and a platform base which supports a main base, saidplatform having at least one intake port; a motor carried by saidplatform base, said motor rotating a ventilation fan having a pluralityof radial vanes with a fan aperture centrally positioned therein, saidventilation fan drawing air in through said at least one intake port; afan shroud enclosing said ventilation fan and having a shroud opening,wherein said fan shroud extends from said platform base toward saidplatform bottom, said main base surrounding said motor, said main basehaving an outer housing with at least one housing port, wherein rotationof said ventilation fan draws air into said fan aperture from said atleast one intake port, through said shroud opening, and expels the airradially from said plurality of radial vanes so that the air flowsthrough said motor and out said at least one housing port; a casing thatencloses portions of said motor, wherein said casing is positionedbetween said motor and outer housing and said casing includes aplurality of passages through which air passes from said platformthrough said at least one housing port; a brush bracket disposed at oneend of said motor; an end bracket disposed at an opposite end of saidmotor; and at least one fastener connecting said brush bracket, saidcasing and said end bracket to each other.
 2. The appliance according toclaim 1, further comprising: a fan end plate positioned between saidventilation fan and said motor, said fan end plate having at least oneplate aperture therethrough, wherein air drawn in through said fanshroud passes through said at least one plate aperture.
 3. The applianceaccording to claim 1, further comprising: an inner support radiallypositioned entirely around said casing and is positioned in between saidcasing and at least one of said main base and said platform, said innersupport and said main base forming a chamber therebetween, wherein saidat least one housing port is contiguous with and radially adjacent saidchamber.
 4. The appliance according to claim 1, further comprising: aninner support positioned between said casing and one of said main baseand said platform, wherein air flows through said plurality of passagesto an exterior of said inner support and through said at least onehousing port.
 5. The appliance according to claim 2, wherein said fanaperture is aligned with said shroud opening, wherein rotation of saidventilation fan draws in air through said at least one air intake port,through said shroud opening into said fan aperture, and wherein saidplurality of radial vanes expel the air radially, whereupon the airpasses through said at least one plate aperture.
 6. The applianceaccording to claim 1, wherein said fan aperture is aligned with saidshroud opening.
 7. An appliance, comprising: a main base; a platformhaving a platform bottom and a platform base which supports said mainbase, said platform having at least one intake port; a motor carried bysaid platform base and extending into said main base, said motorrotating a ventilation fan that draws air in through said at least oneintake port; a fan shroud carried by said platform base and enclosingsaid ventilation fan, said fan shroud having a centrally disposed shroudopening, wherein said fan shroud extends from said platform base towardsaid platform bottom, wherein said centrally disposed shroud openingfaces said platform bottom and said main base surrounds said motor, saidmain base having an outer housing with at least one housing port,wherein rotation of said ventilation fan draws air from said at leastone intake port, through said centrally disposed shroud opening, andexpels the air through said motor, into said main base and out said atleast one housing port; a casing that encloses portions of said motor,wherein said casing is positioned between said motor and said outerhousing and said casing includes a plurality of passages through whichair passes from said platform through said at least one housing port; abrush bracket disposed at one end of said motor; an end bracket disposedat an opposite end of said motor; and at least one fastener connectingsaid brush bracket, said casing and said end bracket to each other. 8.The appliance according to claim 7, further comprising: a fan end platepositioned between said ventilation fan and said motor, said fan endplate having at least one plate aperture therethrough, wherein air drawnin through said fan shroud passes through said at least one plateaperture.
 9. The appliance according to claim 7, further comprising: aninner support radially positioned entirely around said casing and ispositioned between said casing and at least one of said main base andsaid platform, said inner support and said main base forming a chambertherebetween, wherein said at least one housing port is contiguous withand radially adjacent said chamber.
 10. The appliance according to claim7, wherein said ventilation fan has a plurality of radial vanes with afan aperture centrally positioned therein and which is aligned with saidcentrally disposed shroud opening, wherein rotation of said ventilationfan draws in air through said at least one air intake port, through saidcentrally disposed shroud opening into said ventilation fan, and whereinsaid plurality of radial vanes expel the air radially, whereupon the airpasses through said motor, into said main base and out said at least onehousing port.
 11. The appliance according to claim 7, wherein saidventilation fan has a plurality of radial vanes with a fan aperturecentrally positioned therein and which is aligned with said centrallydisposed shroud opening.
 12. An appliance, comprising: a platform havinga platform bottom and a platform base which supports a main base, saidplatform having at least one intake port; a motor carried by saidplatform base, said motor rotating a ventilation fan having a pluralityof radial vanes with a fan aperture centrally positioned therein, saidventilation fan drawing air in through said at least one intake port; afan shroud enclosing said ventilation fan and having a shroud opening,wherein said fan shroud extends from said platform base toward saidplatform bottom, said main base surrounding said motor, said main basehaving an outer housing with at least one housing port, wherein rotationof said ventilation fan draws air into said fan aperture from said atleast one intake port, through said shroud opening, and expels the airradially from said plurality of radial vanes so that the air flowsthrough said motor and out said at least one housing port; a casing thatencloses portions of said motor, wherein said casing provides pluralityof passages through which air passes from said platform through said atleast one housing port; a fan end plate positioned between saidventilation fan and said motor, said fan end plate having at least oneplate aperture therethrough, wherein air drawn in through said fanshroud passes through said at least one plate aperture; an inner supportpositioned between said casing and at least one of said main base andsaid platform, said inner support and said main base forming a chambertherebetween, wherein said at least one housing port is contiguous withsaid chamber; a brush bracket disposed at one end of said motor; an endbracket disposed at an opposite end of said motor; and at least onefastener connecting said brush bracket, said casing and said end bracketto each other.
 13. The appliance according to claim 12, wherein said fanaperture is aligned with said shroud opening, wherein rotation of saidventilation fan draws in air through said at least one air intake port,through said shroud opening into said fan aperture, and wherein saidplurality of radial vanes expel the air radially, whereupon the airpasses through said at least one plate aperture.